An additive manufacturing system may include an additive manufacturing apparatus on which a process of producing a three-dimensional object from a material can be performed; an additive manufacturing process controller operatively associated with the additive manufacturing apparatus; and a first memory device operatively associated with the additive manufacturing process controller. The first memory device may include first and second stable release process programs each comprising a first subset of operations executable by said process controller. The system may include a second memory device comprising another stable release process program comprising a second subset of operations executable by said process controller. The system may include a selector configured to choose one of the stable release process programs to run on said process controller when producing a three-dimensional object on the additive manufacturing apparatus.
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2. The additive manufacturing system of claim 1, wherein each of said first, second, and third stable release process programs is configured to generate a process of producing the three-dimensional object based on (i) a specific geometry of said three-dimensional object to be produced, (ii) specific characteristics of the material from which said three-dimensional object is to be produced, and (iii) a specific structural configuration of the additive manufacturing apparatus on which the process is carried out.
This invention relates to additive manufacturing systems designed to produce three-dimensional objects with improved process stability. The system addresses challenges in maintaining consistent production quality across different geometries, materials, and machine configurations. The core innovation involves a set of stable release process programs tailored to specific conditions. Each program generates a production process that accounts for three key factors: the geometry of the object being manufactured, the material properties of the object, and the structural configuration of the additive manufacturing apparatus. By integrating these variables, the system ensures reliable and repeatable production outcomes. The programs are pre-configured to optimize parameters such as layer thickness, print speed, and temperature settings based on the input parameters, reducing variability and defects in the final product. This approach enhances manufacturing efficiency and product consistency, particularly in industries requiring high precision, such as aerospace, medical devices, and automotive components. The system's adaptability to different materials and machine setups makes it versatile for various additive manufacturing applications.
3. The additive manufacturing system of claim 1, wherein said selector is configured to choose one of said first, second, or third stable release process programs to run on said additive manufacturing process controller responsive to user input received by said fourth stable release process program.
Additive manufacturing systems are used to build three-dimensional objects by sequentially depositing material based on digital models. A key challenge is ensuring consistent and reliable operation across different process programs, which may vary in stability and functionality. This invention addresses this by providing an additive manufacturing system with multiple stable release process programs and a selector mechanism that allows users to choose between them. The system includes an additive manufacturing process controller that executes process programs to control the manufacturing process. At least three stable release process programs are stored in memory, each representing a different version or configuration of the manufacturing process. A selector is configured to choose one of these programs to run on the controller based on user input received by a fourth stable release process program. This fourth program acts as an interface, allowing users to select the desired process program for execution. The selector ensures that only stable, tested versions of the process programs are used, reducing the risk of errors or inconsistencies during manufacturing. The system may also include a display for presenting the available process programs to the user, enhancing usability and control. This approach improves reliability and flexibility in additive manufacturing by enabling users to switch between different stable process configurations as needed.
4. The additive manufacturing system of claim 1, wherein said at least one first memory device comprises at least two first memory devices, and wherein said first stable release process program is stored on a different first memory device than said second stable release process program.
Additive manufacturing systems face challenges in managing and executing multiple stable release process programs, particularly when different programs must be isolated to prevent interference or corruption. This invention addresses the need for reliable program storage and execution in additive manufacturing by implementing a system with at least two separate memory devices. Each memory device stores a distinct stable release process program, ensuring that the programs are physically isolated from one another. This isolation prevents unintended interactions or conflicts between programs, enhancing system stability and reliability. The system may include additional components such as a controller, a build platform, and an energy source, which work together to execute the stored programs for additive manufacturing processes. By distributing the programs across multiple memory devices, the system ensures that each program operates independently, reducing the risk of errors or failures during manufacturing operations. This approach is particularly useful in environments where different process programs must be maintained separately, such as in industrial or high-precision additive manufacturing applications.
5. The additive manufacturing system of claim 1, wherein said additive manufacturing apparatus comprises a removable window cassette, and each of said first, second, and third stable release process programs is configured to generate a process of producing the three-dimensional object based on a window cassette type of the removable window cassette and/or a specific window identity of the removable window cassettes.
This invention relates to additive manufacturing systems, specifically addressing the challenge of optimizing build processes based on removable window cassettes used in the system. The system includes an additive manufacturing apparatus with a removable window cassette, which is a component that interfaces with the build chamber and may vary in type or identity. The system is configured to execute multiple stable release process programs, each tailored to generate a three-dimensional object production process based on the specific window cassette type or a unique window identity. This ensures compatibility and optimal performance by adjusting parameters such as energy input, cooling rates, or material deposition strategies according to the cassette's characteristics. The system may also include a build platform, a material delivery system, and a control unit that manages the process programs. The removable window cassette allows for modularity, enabling different cassettes to be used for various materials or build conditions without requiring extensive system recalibration. The invention improves efficiency and reliability in additive manufacturing by dynamically adapting the build process to the specific cassette in use.
6. The additive manufacturing system of claim 1, wherein each of said first, second, and third stable release process programs is configured to generate a process of producing a three-dimensional object based on current data on a status or performance of the additive manufacturing apparatus on which the process is carried out.
This invention relates to additive manufacturing systems designed to optimize the production of three-dimensional objects by dynamically adjusting process parameters based on real-time status or performance data of the manufacturing apparatus. The system includes multiple stable release process programs, each tailored to generate a specific production process for a three-dimensional object. These programs are configured to incorporate current data on the status or performance of the additive manufacturing apparatus, such as temperature, material flow rate, or mechanical stability, to ensure consistent and high-quality output. The system may also include a process program selection unit that selects the most suitable process program based on the current conditions of the apparatus, ensuring adaptability to varying operational parameters. Additionally, the system may feature a process program generation unit that creates new process programs by combining or modifying existing ones, allowing for continuous improvement and customization. The invention aims to enhance the reliability and efficiency of additive manufacturing by dynamically adjusting processes to match real-time operational conditions, reducing defects and improving overall production quality.
8. The additive manufacturing system of claim 7, wherein said selector is configured to choose one of said first, second, or third stable release process programs to run on said additive manufacturing process controller based on a result of said comparator.
Additive manufacturing systems, particularly those using powder-based processes, often face challenges in maintaining consistent material release during the build process. Variations in powder properties, environmental conditions, or machine settings can lead to defects or failures. To address this, a system has been developed that includes multiple stable release process programs, each optimized for different conditions. A comparator monitors real-time process parameters such as temperature, humidity, or powder flow rate and compares them against predefined thresholds. A selector then chooses the most appropriate stable release process program based on the comparator's output. This ensures that the additive manufacturing process controller executes the optimal program for the current conditions, improving build quality and reliability. The system may also include feedback mechanisms to adjust parameters dynamically, further enhancing consistency. By dynamically selecting the best process program, the system minimizes defects and improves the overall efficiency of the additive manufacturing process.
9. The additive manufacturing system of claim 1, wherein said at least one first memory device is configured to communicate with said additive manufacturing process controller via the Internet.
This invention relates to additive manufacturing systems, specifically those that enable remote monitoring and control of the manufacturing process. The system addresses the challenge of ensuring real-time data access and control over additive manufacturing processes, which is critical for quality assurance, process optimization, and remote operation. The system includes an additive manufacturing process controller that manages the fabrication process, at least one first memory device that stores data related to the manufacturing process, and a communication interface that allows the memory device to interact with the controller. The key innovation is that the first memory device is configured to communicate with the additive manufacturing process controller via the Internet, enabling remote access to process data, control commands, and system diagnostics. This remote connectivity allows operators, engineers, or automated systems to monitor and adjust the manufacturing process from any location, improving flexibility and efficiency. The system may also include additional memory devices for storing different types of data, such as machine settings, material properties, or historical performance data, all of which can be accessed and managed remotely. The Internet-based communication ensures seamless integration with cloud-based platforms, enterprise systems, or other remote monitoring tools, enhancing the overall functionality and scalability of the additive manufacturing system.
10. The additive manufacturing system of claim 1, wherein said first, second, and third stable release process programs were received by the at least one first memory device via the Internet.
Additive manufacturing systems, particularly those using multiple stable release process programs, face challenges in efficiently managing and distributing these programs across different components. The invention addresses this by providing an additive manufacturing system where the first, second, and third stable release process programs are received by at least one first memory device via the Internet. These programs control the additive manufacturing process, ensuring consistent and reliable operation. The system includes a controller that executes these programs to manage the manufacturing process, including material deposition, layer formation, and quality control. The Internet-based distribution allows for centralized updates, remote monitoring, and seamless integration with cloud-based or networked manufacturing environments. This approach enhances flexibility, reduces downtime, and ensures that all components operate with the latest process parameters. The system may also include additional memory devices and controllers to support distributed processing and redundancy, improving overall system reliability. By leveraging Internet-based program delivery, the invention streamlines the deployment and maintenance of additive manufacturing processes, making it suitable for industrial applications requiring high precision and adaptability.
12. The additive manufacturing system of claim 11, wherein each said first, second, and third stable release process program each includes an input configured to acquire resin characteristic data based on a corresponding material batch unique identifier, and modify the process of producing the three-dimensional object on each said additive manufacturing apparatus based on said material characteristic data.
This invention relates to an additive manufacturing system that produces three-dimensional objects using multiple additive manufacturing apparatuses. The system addresses the challenge of maintaining consistent print quality across different batches of resin materials, which can vary in properties such as viscosity, curing rate, and mechanical strength. Each additive manufacturing apparatus in the system operates using a stable release process program that controls the production process. The system includes a first, second, and third stable release process program, each associated with a different additive manufacturing apparatus. Each program is configured to acquire resin characteristic data based on a unique identifier for the material batch being used. The system then modifies the production process for each apparatus based on the specific resin characteristics of the batch, ensuring optimal printing conditions. This approach allows the system to adapt to variations in material properties, improving print accuracy and reducing defects. The invention enhances the reliability of additive manufacturing by dynamically adjusting process parameters to match the unique properties of each resin batch.
13. The additive manufacturing system of claim 1, wherein each said additive manufacturing apparatus comprises a stereolithography apparatus.
This invention relates to additive manufacturing systems, specifically those using multiple stereolithography (SLA) apparatuses to produce three-dimensional objects. The system addresses the challenge of efficiently manufacturing multiple parts simultaneously while maintaining precision and consistency. Each SLA apparatus in the system uses a light source to cure photopolymer resin layer by layer, building objects from a digital model. The system coordinates these apparatuses to work in parallel, allowing for high-throughput production of identical or varied parts. The use of SLA technology ensures high-resolution, detailed outputs, making the system suitable for applications requiring fine features or complex geometries. The system may also include mechanisms for material handling, such as resin dispensing and part removal, to streamline the manufacturing process. By integrating multiple SLA devices, the system enhances productivity without sacrificing the accuracy and surface finish characteristic of stereolithography. This approach is particularly useful in industries like aerospace, medical devices, and prototyping, where rapid, precise production of multiple parts is essential. The system may further include control software to manage the operation of each SLA apparatus, ensuring synchronization and quality control across all units.
14. The additive manufacturing system of claim 1, wherein said material comprises a photopolymerizable resin.
Additive manufacturing systems, particularly those using photopolymerization, face challenges in achieving precise material deposition and curing while maintaining structural integrity. Traditional systems often struggle with inconsistent curing rates, material waste, or limited material compatibility. This invention addresses these issues by incorporating a photopolymerizable resin as the build material in an additive manufacturing system. The resin is selectively cured using light, typically from a UV or visible light source, to solidify the material layer by layer. The system includes a build platform, a resin supply mechanism, and a light source that precisely controls the curing process. The photopolymerizable resin allows for high-resolution printing, rapid prototyping, and the creation of complex geometries with fine details. The system may also include a leveling mechanism to ensure uniform resin distribution and a heating element to control resin viscosity. By using a photopolymerizable resin, the system achieves faster curing times, reduced material waste, and improved material properties compared to traditional methods. The invention is particularly useful in applications requiring high precision, such as dental prosthetics, microelectronics, and aerospace components.
16. The system of claim 15, wherein each of said first, second, and third stable release process programs is configured to generate operating instructions based on (i) a specific geometry of the three-dimensional object to be produced, (ii) specific characteristics of a material from which said three-dimensional object is to be produced, and (iii) a specific structural configuration of an additive manufacturing apparatus on which the additive manufacturing production process is carried out.
This invention relates to additive manufacturing systems designed to produce three-dimensional objects with improved stability and precision. The system addresses challenges in maintaining consistent production quality by integrating multiple stable release process programs that adapt to specific manufacturing conditions. Each program generates operating instructions tailored to the geometry of the object being produced, the material properties of the production material, and the structural configuration of the additive manufacturing apparatus. The system ensures that the production process remains stable by dynamically adjusting parameters such as layer deposition, curing, or solidification based on real-time feedback from sensors monitoring the manufacturing environment. The programs also account for variations in material behavior, such as thermal expansion or viscosity, to prevent defects like warping or delamination. By combining these adaptive processes with the apparatus's structural capabilities, the system optimizes build accuracy and repeatability across different production scenarios. The invention is particularly useful in industries requiring high-precision manufacturing, such as aerospace, medical devices, and automotive components, where material consistency and structural integrity are critical.
17. The system of claim 15, wherein each of said first, second, and third stable release process programs is configured to generate operating instructions based on attributes of an additive manufacturing apparatus that produces the three-dimensional object.
This invention relates to additive manufacturing systems, specifically addressing the challenge of managing multiple stable release process programs to ensure consistent and reliable production of three-dimensional objects. The system includes a control module that executes at least three distinct stable release process programs, each designed to generate operating instructions tailored to the specific attributes of an additive manufacturing apparatus. These attributes may include machine capabilities, material properties, and environmental conditions. The system dynamically selects and applies the most appropriate process program based on real-time data, ensuring optimal performance and quality control. Each process program is configured to adapt to variations in the additive manufacturing apparatus, such as changes in build parameters or material characteristics, to maintain precision and repeatability. The invention enhances production efficiency by minimizing errors and reducing the need for manual adjustments, thereby improving the overall reliability of additive manufacturing processes.
18. The system of claim 15, wherein each of said first, second, and third stable release process programs is configured to generate operating instructions based on current data on the status or performance of the additive manufacturing apparatus on which the process is carried out.
This invention relates to additive manufacturing systems, specifically those using multiple stable release process programs to optimize printing operations. The system addresses the challenge of maintaining consistent and high-quality additive manufacturing by dynamically adjusting process parameters based on real-time data. Each of the first, second, and third stable release process programs is designed to generate operating instructions tailored to the current status or performance of the additive manufacturing apparatus. These programs monitor factors such as machine conditions, material properties, and environmental variables to ensure optimal printing conditions. By continuously updating the operating instructions, the system adapts to variations in the manufacturing process, reducing defects and improving efficiency. The programs may also incorporate feedback loops to refine their instructions over time, enhancing overall system reliability. This approach ensures that the additive manufacturing process remains stable and precise, even under varying operational conditions. The invention is particularly useful in industrial settings where consistency and quality control are critical.
19. The system of claim 15, wherein each of said first, second, and third stable release process programs is configured to acquire material characteristic data based on a corresponding material batch unique identifier, and generate operating instructions based on said material characteristic data, wherein said material characteristic data describes at least one property of a material used in the additive manufacturing production process to produce the three-dimensional object.
This invention relates to additive manufacturing systems, specifically those involving multiple stable release process programs for producing three-dimensional objects. The system addresses the challenge of ensuring consistent material properties and production quality by dynamically adjusting operating instructions based on material characteristics. The system includes at least three stable release process programs, each responsible for a distinct phase of the additive manufacturing process. Each program is configured to acquire material characteristic data using a unique identifier for each material batch. This data describes properties such as composition, viscosity, or thermal behavior, which are critical for optimizing the production process. Based on this data, the programs generate precise operating instructions for the additive manufacturing equipment, ensuring that the material is processed correctly to produce the desired three-dimensional object. By linking material batch identifiers to specific process parameters, the system enables real-time adjustments to compensate for variations in material properties. This approach improves production consistency, reduces defects, and enhances the reliability of additive manufacturing processes. The invention is particularly useful in industries where material uniformity is critical, such as aerospace, medical devices, and high-precision engineering.
20. The system of claim 19, wherein said material characteristic data is acquired from a material database, said material database comprising material characteristic data for different material batches, each different material batch assigned a material batch unique identifier, and wherein said material comprises a photopolymerizable resin.
This invention relates to a system for managing material characteristics in additive manufacturing, particularly for photopolymerizable resins. The system addresses the challenge of ensuring consistent material properties across different batches of photopolymer resins, which is critical for maintaining print quality and reliability in 3D printing applications. The system includes a material database that stores characteristic data for various resin batches, with each batch assigned a unique identifier to track and differentiate them. The database allows users to access specific material properties, such as viscosity, curing behavior, or mechanical strength, associated with each batch. By integrating this database with additive manufacturing processes, the system enables precise material selection and quality control, reducing variability in printed parts. The use of photopolymerizable resins, which cure under light exposure, further emphasizes the need for accurate batch tracking to ensure optimal printing conditions. This approach enhances reproducibility and traceability in additive manufacturing workflows, particularly in industries where material consistency is critical, such as aerospace, medical devices, or high-precision engineering.
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December 13, 2019
May 14, 2024
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